[Dree]

My Hihy just started exhibiting these problems and I am about 4 months too late to qualify for the free replacement, primary coverage was until December 31, 2020! It only has 80,200 miles on it and was purchased in May 2009 so, it already has 12 years on it so it doesn't qualify for the secondary coverage either. Took it to the dealership and they initially estimated over $3,800 to fix it! After a bunch of research and convincing, I got them to go down to $2,272.89, but it's still a lot of money, considering these two parts (actuator and pump), are known to cause trouble, hence the extended warranty. I already filed a complaint with Toyota and the NHTSA since I believe this is a safety issue and should've been a recall, NOT an extended warranty. I am considering DIY-ing it but, the lowest I could find for the new genuine second generation parts is $1,572.16 plus the Toyota software, diagnostic cable and brake fluid, everything comes up at $1,681.75. I'm taking it to my local hybrid repair shop on Wednesday to get their estimate and then decide on what to do. If anyone has any advice or know any loopholes I don't know of, I'd appreciate the input. I already called Toyota and they said there's nothing they could do for me, thinking they could extend the warranty period because of the pandemic or something, but no luck there.

 

[whosurpopi]

If this is the right part number,
44050-48320 Then this is where I got mine, and it is only $1075.

2008-2019 Toyota Highlander ABS Modulator Valve 44050-48320 | Toyota Parts Center

 

[Dree]

If this is the right part number,
44050-48320 Then this is where I got mine, and it is only $1075.

2008-2019 Toyota Highlander ABS Modulator Valve 44050-48320 | Toyota Parts Center

I am interested in the new second generation part number 04008-26448 which is supposed to replace part number 44050-48320. I actually found it listed for $1,052 but adding the pump, part number 04008-51148 which I found for $567, it all adds up to the grand total I previously specified.

 

[whosurpopi]

I only replaced the one part. Has been working perfectly for almost two years.

 

[Dree]

I only replaced the one part. Has been working perfectly for almost two years.

Really? Thanks for the feedback, I will be looking into replacing just the actuator then if the pump is still good.

 

[safetyfirst]

It is completely ridiculous that Toyota used a "Customer Support Program" expiring December 31, 2020, as a response to this safety defect instead of issuing a recall. My 2008 Toyota Highlander Hybrid's brake actuator assembly experienced this malfunction earlier this month, missing the cutoff for the program by just under 9 months. The defective part is a safety hazard because the error codes disable the vehicle's ABS and VSC systems. From what I've been told, it also disables the vehicle's regenerative braking system, which means that you'll likely discharge and potentially damage the hybrid battery unless you start the vehicle with the hybrid system off.

I just filed this complaint with the National Highway Traffic Safety Administration (NHTSA), which should go online in a couple of days:

On approx. August 13, 2021, my 2008 Toyota Highlander Hybrid vehicle began making grinding sounds when the brake is fully depressed while the transmission lever is set to "drive".

On approx. August 20, 2021, my vehicle started showing 4 error messages on the display: Brake Malfunction, Check ABS, Check VSC System, and Check Brake System. The Brake Malfunction error was displayed with a warning to "Stop the vehicle in a safe place immediately, and contact a dealer". At the same time, these 5 warning lamps became illuminated: Brake System Warning Light and Warning Buzzer (Red), Brake System Warning Light (Yellow), Master Warning Light (Yellow), ABS Warning Light (Yellow), and SLIP Indicator (Yellow). A car repair technician obtained the following error codes from the vehicle in a diagnosis: C1241 (Low or High Power Supply Voltage), C1253 (Pump Motor Relay), and C1391 (Abnormal Leak in Accumulator). I was informed that the VSC (vehicle stability control) safety feature of the vehicle is disabled while the error codes and messages are present.

Toyota previously issued a customer support bulletin (No. POL19-06) on June 6, 2019, titled "Customer Support Program ZKC: Certain 2008-2010 Model Year Highlander Hybrid Vehicles Coverage for Brake Actuator Assembly and Brake Booster Pump Assembly". In the bulletin, Toyota acknowledged that its 2008-2010 Highlander Hybrid models had "certain internal malfunctions of the Brake Actuator Assembly". Affected error codes include C1391 and C1253, among others. Affected warning lamps consists of all 5 of the warning lamps that were illuminated in my vehicle. Affected parts include 04008-26448 (Actuator Assy, Brake w/ Fluid) and 04008-51148 (Pump Kit, Brake Booster w/ Accumulator).

Instead of issuing a recall for this hazardous defect, Toyota opted to offer "Customer Support Program ZKC". The malfunction that manifested my vehicle is not eligible for this program. Toyota should issue a proper recall to address this safety hazard.

I added 5 attachments to my complaint:

1. Toyota Customer Support Program ZKC - Dealer letter: https://static.nhtsa.gov/odi/tsbs/2019/MC-10164924-9999.pdf
2. Toyota Customer Support Program ZKC - Bulletin: https://static.nhtsa.gov/odi/tsbs/2019/MC-10164925-9999.pdf
3. Vehicle diagnostic report from the Toyota Techstream software, showing the error codes
4. Photo of the "Brake Malfunction" error on the display
5. Photo of the warning lamps on the dashboard

We're not alone. When I scroll through the list of complaints for the 2008 Toyota Highlander Hybrid at 2008 TOYOTA HIGHLANDER HYBRID 4 DR AWD | NHTSA, I see that a staggering 134 complaints have been submitted about the service brakes for this model year alone, including 8 complaints in 2021 so far about this exact issue after "Customer Support Program ZKC" expired for this model year. Some complaints (such as the August 20, 2021 one) say that the owner needed to replace the brake actuator and brake booster more than once because the part failed repeatedly.

The 2009, 2010, 2011, 2012, and 2013 models have additional complaints:

• 2009 Toyota Highlander Hybrid (25 complaints about service brakes, including 2 in 2021 to date): 2009 TOYOTA HIGHLANDER HYBRID 4 DR FWD/AWD | NHTSA
• 2010 Toyota Highlander Hybrid (18 complaints about service brakes, including 4 in 2021 to date): 2010 TOYOTA HIGHLANDER HYBRID 4 DR FWD/AWD | NHTSA
• 2011 Toyota Highlander Hybrid (12 complaints about service brakes): 2011 TOYOTA HIGHLANDER HV SUV AWD | NHTSA
• 2012 Toyota Highlander Hybrid (7 complaints about service brakes): 2012 TOYOTA HIGHLANDER HV SUV AWD | NHTSA
• 2013 Toyota Highlander Hybrid (14 complaints about service brakes): 2013 TOYOTA HIGHLANDER HV SUV AWD | NHTSA

If you have a second-generation Toyota Highlander Hybrid that was affected by this malfunction, please do us all a favor and file a complaint with the NHTSA at Report a Safety Problem | NHTSA so that the NHTSA can order Toyota to recall this vehicle. Please submit a report even if you had your vehicle serviced through the "Customer Support Program". All safety hazards need a proper recall, and Toyota's "Customer Support Program ZKC" is not an adequate substitute for a recall.

 

[vxkumar]

I have the same problem with my 2008 HiHy with 145000 miles on it. On November 26, 2021 started displaying Check ABS, Check VSC System, Check Brake System and Brake Malfunction, errors on the display screen. I could feel the the grinding noise and brake pedal seemed different than normal. The dealer is charging $4000 and I am not covered under extended warranty. The parts Brake Actuator Assembly (44050-48320) (2008-2019 Toyota Highlander Actuator Assembly, Brake 44050-48320 | Grieco Toyota Parts) and Power Brake Booster (47070-48020) (2008-2010 Toyota Highlander Power Brake Booster 47070-48020 | Grieco Toyota Parts) themself are ~$1600.
Any ideas on how to fix this? Is it possible Toyota can make exception and dealership fix it?

 

[hman88]

I have the same problem with my 2008 HiHy with 145000 miles on it. On November 26, 2021 started displaying Check ABS, Check VSC System, Check Brake System and Brake Malfunction, errors on the display screen. I could feel the the grinding noise and brake pedal seemed different than normal. The dealer is charging $4000 and I am not covered under extended warranty. The parts Brake Actuator Assembly (44050-48320) (2008-2019 Toyota Highlander Actuator Assembly, Brake 44050-48320 | Grieco Toyota Parts) and Power Brake Booster (47070-48020) (2008-2010 Toyota Highlander Power Brake Booster 47070-48020 | Grieco Toyota Parts) themself are ~$1600.
Any ideas on how to fix this? Is it possible Toyota can make exception and dealership fix it?

Sorry to hear about that! I would recommend filing a complaint with the NHTSA if you haven't already done so. 2008+ owners please file a complaint with NHTSA

Hopefully Toyota can be held accountable and obligated to issue a recall for our model/years as they have done for other models/years.

It shouldn't be too difficult to replace the components if your are fairly mechanically inclined. https://www.youtube.com/results?search_query=toyota+hybrid+brake+actuator+booster++replacement

Bleeding the system on hybrids is going to be the biggest hurdle if you don't have access to a diagnostic tool.

 

[vxkumar]

Sorry to hear about that! I would recommend filing a complaint with the NHTSA if you haven't already done so. 2008+ owners please file a complaint with NHTSA

Hopefully Toyota can be held accountable and obligated to issue a recall for our model/years as they have done for other models/years.

It shouldn't be too difficult to replace the components if your are fairly mechanically inclined. https://www.youtube.com/results?search_query=toyota+hybrid+brake+actuator+booster++replacement

Bleeding the system on hybrids is going to be the biggest hurdle if you don't have access to a diagnostic tool.

Thank you for the information you shared.

I called toyota, spent more than an hour on phone with them to raise my issue. The representative was not able to make a decision on my case so she transferred me to her manager. The manager said that toyota was very generous to extend the warranty which expired on 12/31/2020. I asked him to make exception because due to covid everything was shut down, car was not driven anywhere and it only make logical to extend the warranty. He replied the same and told me that if they open another recall/warranty they would let me know. So, they can do nothing.

I have raised complaint with NHTSA and suggested them to make this a recall.

Since dealerships are asking too much money, I am going to replace the parts myself with OEM parts.

However, I have confusion in parts. There are two numbers for the same part:

1) Actuator: 04008-26448 and 44050-48320
2) Pump: 04008-51148 and 47070-48020

I am not clear which part to order.

I understand that 44050-48320 and 47070-48020 are the ones what were originally installed in factory during manufacturing and 04008-26448 and 04008-51148 are kind of upgrade because these are mentioned in the Customer Support Program Bulletin (https://static.nhtsa.gov/odi/tsbs/2019/MC-10164925-9999.pdf) as replacements which requires a 2 hours labor time for technician. My dealership are charging 5 hours of labor. According to car care nut on youtube any toyota part starting with 04008 is actually an assembly kit which is a combination of the same parts but already assembled and might be cheaper compared to ordering parts separately and assembling yourself.

My hypothesis is that parts 04008-26448 and 04008-51148 are prefilled with brake fluid and the dealership just replace these without bleeding the abs. My dealership told me that they will replace with 44050-48320 and 47070-48020 only because they use 04008-26448 and 04008-51148 when they follow Customer Support Program Bulletin and make a claim with Toyota. Has somebody replaced their abs parts out with 04008-26448 and 04008-51148, what is the actual part number printed on the actuator and pump assembly? Are 04008-26448 and 04008-51148 really designed better than 44050-48320 and 47070-48020 and do not fail?

 

[safetyfirst]

I followed whosurpopi's and Dree's advice, and only got the new Brake Actuator Assembly model (04008-26448, "Actuator Assy, Brake w/ Fluid"). Then, I went to a local auto repair shop that specializes in hybrid vehicles, and they did the replacement in a couple of hours. That fixed the issue, and my Highlander has been running well ever since.

I would definitely not order the old Brake Actuator Assembly model (44050-48320). It doesn't seem to be much cheaper, if at all, and the reports of that model repeatedly failing are really concerning to me.

If you just search "04008-26448" (the part number of the new model) on the web, there are many dealerships that sell the genuine Toyota part at an online-only price. Find the one that has the lowest combined cost (price + shipping) for your location and order from them. It took me two tries to get the order through. The first time, the dealership refused to sell the part to me because it was listed as a "campaign part" (ironic because the fact that the campaign expired for me is the reason I need the part). The second dealership shipped the part to me after I confirmed the Highlander's VIN.

I did not buy the Brake Booster Pump Assembly (04008-51148, "Pump Kit, Brake Booster w/ Accumulator"). It apparently wasn't necessary to fix the issue. I also chose specifically to go to a local auto repair shop that was not a dealership because I am dissatisfied with the way Toyota handled this safety issue. I made sure to request a printout of the error codes (generated through the Toyota Techstream software) from the auto repair shop before they started the replacement, so that I would be reimbursed for the part and labor in case this situation eventually becomes a recall.

 

[daorders242]

I followed whosurpopi's and Dree's advice, and only got the new Brake Actuator Assembly model (04008-26448, "Actuator Assy, Brake w/ Fluid"). Then, I went to a local auto repair shop that specializes in hybrid vehicles, and they did the replacement in a couple of hours. That fixed the issue, and my Highlander has been running well ever since.

I would definitely not order the old Brake Actuator Assembly model (44050-48320). It doesn't seem to be much cheaper, if at all, and the reports of that model repeatedly failing are really concerning to me.

If you just search "04008-26448" (the part number of the new model) on the web, there are many dealerships that sell the genuine Toyota part at an online-only price. Find the one that has the lowest combined cost (price + shipping) for your location and order from them. It took me two tries to get the order through. The first time, the dealership refused to sell the part to me because it was listed as a "campaign part" (ironic because the fact that the campaign expired for me is the reason I need the part). The second dealership shipped the part to me after I confirmed the Highlander's VIN.

I did not buy the Brake Booster Pump Assembly (04008-51148, "Pump Kit, Brake Booster w/ Accumulator"). It apparently wasn't necessary to fix the issue. I also chose specifically to go to a local auto repair shop that was not a dealership because I am dissatisfied with the way Toyota handled this safety issue. I made sure to request a printout of the error codes (generated through the Toyota Techstream software) from the auto repair shop before they started the replacement, so that I would be reimbursed for the part and labor in case this situation eventually becomes a recall.

What is the name of the online dealer you ordered the actuator from? Having the same problem and need to purchase. Thanks for your post!

 

[daorders242]

I am interested in the new second generation part number 04008-26448 which is supposed to replace part number 44050-48320. I actually found it listed for $1,052 but adding the pump, part number 04008-51148 which I found for $567, it all adds up to the grand total I previously specified.

where did you order 04008-26448 from? Having trouble sourcing this part now.

 

[safetyfirst]

where did you order 04008-26448 from? Having trouble sourcing this part now.

There are a lot of Toyota dealerships that sell the actuator online at a lower price than in person. What I did was look up the part number in quotes:

Google Search

Then, I went through every dealership site in the search results and checked the estimated price, with shipping and tax included. I placed the order on the dealership site that was cheapest for me. Shipping varies based on how far the dealership is from you, so you'll have to check for yourself to see which dealership would get the part to you for the lowest total cost.

 

[daorders242]

Everywhere I try to buy online says they do not stock and have an issue getting the new parts from Toyota. Any suggestions?

 

[jtran69]

I have 2006 HH with brake issue. How do I sign up to get notification from Toyota?